PNOZ s4.

Safety relays

Operating Manual-21890-EN-05
Preface
This document is the original document.
All rights to this documentation are reserved by Pilz GmbH & Co. KG. Copies may be made
for internal purposes. Suggestions and comments for improving this documentation will be
gratefully received.
Pilz®, PIT®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®,
SafetyNET p®, the spirit of safety® are registered and protected trademarks of Pilz GmbH
& Co. KG in some countries.

SD means Secure Digital

PNOZ s4.1

Safety relay PNOZ s4.1

The safety relay provides a safety-related interruption of a safety circuit.
The safety relay meets the requirements of EN 60947-5-1, EN 60204-1 and VDE 0113-1
and may be used in applications with
} E-STOP pushbuttons
} Safety gates
} Light beam devices
It is suitable for use in furnaces in accordance with EN 50156-1.

For your safety

} Only install and commission the unit if you have read and understood these operating
instructions and are familiar with the applicable regulations for health and safety at work
and accident prevention.
Ensure VDE and local regulations are met, especially those relating to safety.
} Any guarantee is rendered invalid if the housing is opened or unauthorised modifica-
tions are carried out.

Unit features
} Positive-guided relay outputs:
– 3 safety contacts (N/O), instantaneous
– 1 auxiliary contact (N/C), instantaneous
} 1 semiconductor output
} Connection options for:
– E-STOP pushbuttons
– Safety gate limit switches
– Reset buttons
– Light beam devices
– PSEN
– Safety valves for furnaces
} A connector can be used to connect 1 PNOZsigma contact expansion module
} Operating modes can be set via rotary switch
} LED indicator for:
– Supply voltage
– Input status, channel 1
– Input status, channel 2
– Switch status of the safety contacts
– Start circuit
– Errors
} Plug-in connection terminals (either spring-loaded terminal or screw terminal)

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Safety features
The relay meets the following safety requirements:
} The circuit is redundant with built-in self-monitoring.
} The safety function remains effective in the case of a component failure.
} The correct opening and closing of the safety function relays is tested automatically in
each on-off cycle.
} The unit has an electronic fuse.

Block diagram/terminal configuration

A1 A2 S11 S12 S21 S22 13 23 33 41






Input Input






K1


expansion
Interface

unit

Power
K2
Reset/
Start

S34 Y32 14 24 34 42

Centre: Front view with cover, right: Front view without cover

*only when UB = 48 – 240 V AC/DC

Function description

} Single-channel operation: no redundancy in the input circuit, earth faults in the start
circuit and input circuit are detected.
} Dual-channel operation without detection of shorts across contacts: redundant input cir-
cuit, detects
– earth faults in the start and input circuit,
– short circuits in the input circuit and, with a monitored start, in the start circuit too.

} Dual-channel operation with detection of shorts across contacts: redundant input cir-
cuit, detects
– earth faults in the start and input circuit,
– short circuits in the input circuit and, with a monitored start, in the start circuit too,
– shorts between contacts in the input circuit.
} Automatic start: Unit is active once the input circuit has been closed.

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} Manual start: Unit is active once the input circuit is closed and then the start circuit is
closed.
} Monitored start with falling edge: Unit is active once
– the input circuit is closed and then the start circuit is closed and opened again.
– the start circuit is closed and then opened again once the input circuit is closed.
} Monitored start with rising edge: Unit is active once the input circuit is closed and
once the start circuit is closed after the waiting period has elapsed (see technical de-
tails).
} Start with start-up test: The unit checks whether safety gates that are closed are
opened and then closed again when supply voltage is applied.
} Increase in the number of available instantaneous safety contacts by connecting con-
tact expander modules or external contactors/relays;
A connector can be used to connect 1 PNOZsigma contact expander module.

Installation
Install base unit without contact expansion module:
} Ensure that the plug terminator is inserted at the side of the unit.
Connect base unit and PNOZsigma contact expansion module:
} Remove the plug terminator at the side of the base unit and at the contact expansion
module.
} Connect the base unit and the contact expansion module to the supplied connector be-
fore mounting the units to the DIN rail.
Installation in control cabinet
} The safety relay should be installed in a control cabinet with a protection type of at least
IP54.
} Use the notch on the rear of the unit to attach it to a DIN rail (35 mm).
} When installed vertically: Secure the unit by using a fixing element (e.g. retaining brack-
et or end angle).
} Push the device upwards or downwards before lifting it from the DIN rail.

Wiring
Please note:
} Information given in the "Technical details" must be followed.
} Outputs 13-14, 23-24, 33-34 are safety contacts; output 41-42 is an auxiliary contact
(e.g. for display).
} Auxiliary contact 41-42 and semiconductor output Y32 should not be used for safety
circuits!
} To prevent contact welding, a fuse should be connected before the output contacts (see
technical details).

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} Calculation of the max. cable length lmax in the input circuit:





Rlmax = max. overall cable resistance (see technical details)
Rl / km = cable resistance/km
} Use copper wire that can withstand 60/75 °C.
} Sufficient fuse protection must be provided on all output contacts with capacitive and in-
ductive loads.
} With UB 48 – 240 VAC/DC: Connect S21 to the protective earth system

Preparing for operation

Operating modes
The operating mode is set via the rotary switch on the unit. You can do this by opening the
cover on the front of the unit.

CAUTION!
Do not adjust the rotary switch during operation, otherwise an error mes-
sage will appear, the safety contacts will open and the unit will not be ready
for operation until the supply voltage has been switched off and then on
again.

Set operating modes

} Switch off supply voltage.
} Select operating mode via the operating mode selector switch "mode".
} If the operating mode selector switch "mode" is in its start position (vertical position), an
error message will appear.

Operating mode Automatic/man- Monitored start Monitored start Automatic start

selector switch ual start rising edge falling edge with start-up test
"mode"
Without detec-        

tion of shorts
across contacts
With detection of        

shorts across
contacts

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Connection
} Supply voltage

Supply voltage AC DC

   

    

} Input circuit

Input circuit Single-channel Dual-channel

E-STOP  
 
without detection of shorts

across contacts
 


E-STOP 

with detection of shorts

across contacts



Safety gate
without detection of shorts
across contacts 
 

 
 


Safety gate
with detection of shorts
across contacts


 



Light beam device or safety 

switch with detection of

shorts across contacts via  

ESPE 

(only when UB = 24 VDC)

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} Reset circuit/feedback loop

Reset circuit/feedback loop Reset circuit Feedback loop

Automatic reset

 

 
  


Manual/monitored reset  
 
 

 
 
 


} Semiconductor output

UB 24 VDC UB 48 - 240 VAC/DC

*Connect together the 0V connections on all

the external power supplies

Information
If a base unit and a contact expansion module from the PNOZsigma range
are connected via the connector, no additional wiring is necessary.

Legend
} S1/S2: E-STOP/safety gate switch
} S3: Reset button
} : Switch operated

} : Gate open

} : Gate closed

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Operation
The unit is ready for operation when the Power LED is permanently lit.
LEDs indicate the status and errors during operation:

LED on

LED flashes

Information
Status indicators and error indicators may occur independently. In the case
of an error display, the "Fault" LED will light or flash (exception: "Supply
voltage too low"). An LED that is also flashing indicates the potential cause
of the error. An LED that is lit and is static indicates a normal operating sta-
tus. Several status indicators and error indicators may occur simultaneously.

Status indicators

Power
Supply voltage is present.

In1
Input circuit at S12 is closed.

In2
Input circuit at S22 is closed.

Out
Safety contacts are closed and semiconductor output Y32 carries a high signal.

Reset
24 V DC is present at S34.

Error indicators

All LEDs off

Diagnostics: Short across contacts/earth fault; unit switched off
} Remedy: Rectify short across contacts/earth fault, switch off supply voltage
for 1 min.

Fault
Diagnostics: Plug terminator not connected
} Remedy: Insert plug terminator, switch supply voltage off and then on
again.

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Fault
Diagnostics: Internal error, unit defective
} Remedy: Switch supply voltage off and then on again, change unit if neces-
sary.

Power
Diagnostics: Supply voltage too low
} Remedy: Check the supply voltage.

In1, In2 alternately

Fault
Diagnostics: Short detected between S12 and S22
} Remedy: Rectify short across contacts, switch supply voltage off and then
on again.

In1

Fault
Diagnostics: Power-up blocked due to short-term interruption at S12; input cir-
cuits not operated simultaneously
} Remedy: Open both input circuits, S12 and S22, simultaneously and then
close again.

In2

Fault
Diagnostics: Power-up blocked due to short-term interruption at S22; input cir-
cuits not operated simultaneously
} Remedy: Open both input circuits, S12 and S22, simultaneously and then
close again.

Reset

Fault
Diagnostics: Position of rotary switch is not permitted or rotary switch was ad-
justed during operation.
} Remedy: Switch supply voltage off and then on again.

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Power, In1, In2, Out, Reset, Fault

Diagnostics: The operating mode selector switch "mode" is in its start position
(vertical position)
} Remedy: Switch off the supply voltage and set the required operating mode
on operating mode selector switch "mode".

Faults - malfunctions
} Contact malfunctions: If the contacts have welded, reactivation will not be possible after
the input circuit has opened.

Service life graph

The service life graphs indicate the number of cycles from which failures due to wear must
be expected. The wear is mainly caused by the electrical load; the mechanical load is negli-
gible.

Example
} Inductive load: 0,2 A
} Utilisation category: AC15
} Contact service life: 1,000,000 cycles
Provided the application requires fewer than 1,000,000 cycles, the PFH value (see techni-
cal details) can be used in the calculation.
To increase the service life, sufficient spark suppression must be provided on all output
contacts. With capacitive loads, any power surges that occur must be noted. With contac-
tors, use freewheel diodes for spark suppression.

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Technical details

General 750124 750154 751124 751154

Approvals CCC, CE, GOST, CCC, CE, GOST, CCC, CE, GOST, CCC, CE, GOST,
TÜV, cULus Listed TÜV, cULus Listed TÜV, cULus Listed TÜV, cULus Listed
Electrical data 750124 750154 751124 751154
Supply voltage
Voltage 24 V 48 - 240 V 24 V 48 - 240 V
Type DC AC/DC DC AC/DC
Voltage tolerance -15 %/+10 % -15 %/+10 % -15 %/+10 % -15 %/+10 %
Output of external – 5,0 VA – 5,0 VA
power supply
(AC)
Output of external 2,5 W 2,5 W 2,5 W 2,5 W
power supply
(DC)
Frequency range – 50 - 60 Hz – 50 - 60 Hz
AC
Residual ripple 20 % 160 % 20 % 160 %
DC
Continuous duty 100 % 100 % 100 % 100 %
Max. inrush current
impulse
Reset circuit 0,20 A 0,20 A 0,20 A 0,20 A
Feedback loop 0,20 A 0,20 A 0,20 A 0,20 A
Max. overall cable
resistance Rlmax
Single-channel at 30 Ohm 30 Ohm 30 Ohm 30 Ohm
UB DC
Single-channel at – 30 Ohm – 30 Ohm
UB AC
Dual-channel 60 Ohm 60 Ohm 60 Ohm 60 Ohm
without detection
of shorts across
contacts at UB
DC
Dual-channel – 60 Ohm – 60 Ohm
without detection
of shorts across
contacts at UB
AC
Dual-channel with 30 Ohm 30 Ohm 30 Ohm 30 Ohm
detection of
shorts across
contacts at UB
DC
Dual-channel with – 30 Ohm – 30 Ohm
detection of
shorts across
contacts at UB
AC

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Electrical data 750124 750154 751124 751154

Voltage at
Input circuit DC 24,0 V 24,0 V 24,0 V 24,0 V
Reset circuit DC 24,0 V 24,0 V 24,0 V 24,0 V
Feedback loop 24,0 V 24,0 V 24,0 V 24,0 V
DC
Current at
Input circuit DC 50,0 mA 50,0 mA 50,0 mA 50,0 mA
Reset circuit DC 50,0 mA 50,0 mA 50,0 mA 50,0 mA
Feedback loop 50,0 mA 50,0 mA 50,0 mA 50,0 mA
Number of output
contacts
Instantaneous 3 3 3 3
safety contacts
(N/O)
Auxiliary contacts 1 1 1 1
(N/C)
Inputs 750124 750154 751124 751154
Number 2 2 2 2
Semiconductor 750124 750154 751124 751154
outputs
Number 1 1 1 1
Voltage 24,0 V 24,0 V 24,0 V 24,0 V
Current 20 mA 20 mA 20 mA 20 mA
Relay outputs 750124 750154 751124 751154
Max. short circuit 1 kA 1 kA 1 kA 1 kA
current IK
Utilisation category
In accordance EN 60947-4-1 EN 60947-4-1 EN 60947-4-1 EN 60947-4-1
with the standard
Auxiliary contacts, 240 V 240 V 240 V 240 V
AC1 at
Min. current 0,01 A 0,01 A 0,01 A 0,01 A
Max. current 1,5 A 1,5 A 1,5 A 1,5 A
Max. power 375 VA 375 VA 375 VA 375 VA
Auxiliary contacts, 24 V 24 V 24 V 24 V
DC1 at
Min. current 0,01 A 0,01 A 0,01 A 0,01 A
Max. current 6,0 A 6,0 A 6,0 A 6,0 A
Max. power 150 W 150 W 150 W 150 W
Safety contacts, 240 V 240 V 240 V 240 V
AC1 at
Max. current 1,5 A 1,5 A 1,5 A 1,5 A
Min. current 0,01 A 0,01 A 0,01 A 0,01 A
Max. power 375 VA 375 VA 375 VA 375 VA
Safety contacts, 24 V 24 V 24 V 24 V
DC1 at
Max. current 6,0 A 6,0 A 6,0 A 6,0 A
Min. current 0,01 A 0,01 A 0,01 A 0,01 A
Max. power 150 W 150 W 150 W 150 W

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Relay outputs 750124 750154 751124 751154

Utilisation category
In accordance EN 60947-5-1 EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
with the standard
Auxiliary contacts, 230 V 230 V 230 V 230 V
AC15 at
Max. current 0,6 A 0,6 A 0,6 A 0,6 A
Auxiliary contacts, 24 V 24 V 24 V 24 V
DC13 (6 cycles/
min) at
Max. current 0,4 A 0,4 A 0,4 A 0,4 A
Safety contacts, 230 V 230 V 230 V 230 V
AC15 at
Max. current 0,6 A 0,6 A 0,6 A 0,6 A
Safety contacts, 24 V 24 V 24 V 24 V
DC13 (6 cycles/
min) at
Max. current 0,4 A 0,4 A 0,4 A 0,4 A
Contact fuse protec-
tion, external safety
contacts
In accordance EN 60947-5-1 EN 60947-5-1 EN 60947-5-1 EN 60947-5-1
with the standard
Blow-out fuse, 6A 6A 6A 6A
quick
Blow-out fuse, 4A 4A 4A 4A
slow
Circuit breaker, 4A 4A 4A 4A
24V AC/DC, char-
acteristic B/C
Contact fuse protec-
tion, external auxilia-
ry contacts
Blow-out fuse, 6A 6A 6A 6A
quick
Blow-out fuse, 4A 4A 4A 4A
slow
Circuit breaker, 4A 4A 4A 4A
24 V AC/DC,
characteristic B/C
Contact material AgCuNi + 0,2 µm AgCuNi + 0,2 µm AgCuNi + 0,2 µm AgCuNi + 0,2 µm
Au Au Au Au

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Conventional ther- 750124 750154 751124 751154

mal current while
loading several
contacts
Ith per contact at UB
AC
Conv. therm. cur- – 6,00 A – 6,00 A
rent with 1 con-
tact
Conv. therm. cur- – 6,00 A – 6,00 A
rent with 2 con-
tacts
Conv. therm. cur- – 4,50 A – 4,50 A
rent with 3 con-
tacts
Ith per contact at UB
DC
Conv. therm. cur- 6,00 A 6,00 A 6,00 A 6,00 A
rent with 1 con-
tact
Conv. therm. cur- 6,00 A 6,00 A 6,00 A 6,00 A
rent with 2 con-
tacts
Conv. therm. cur- 4,50 A 4,50 A 4,50 A 4,50 A
rent with 3 con-
tacts
Times 750124 750154 751124 751154
Switch-on delay
With automatic 170 ms 170 ms 170 ms 170 ms
reset typ.
With automatic 300 ms 300 ms 300 ms 300 ms
reset max.
With automatic 350 ms 350 ms 350 ms 350 ms
reset after power
on typ.
With automatic 600 ms 600 ms 600 ms 600 ms
reset after power
on max.
With manual reset 40 ms 40 ms 40 ms 40 ms
typ.
With manual reset 300 ms 300 ms 300 ms 300 ms
max.
With monitored 35 ms 35 ms 35 ms 35 ms
reset with rising
edge typ.
With monitored 50 ms 50 ms 50 ms 50 ms
reset with rising
edge max.
With monitored 55 ms 55 ms 55 ms 55 ms
reset with falling
edge typ.
With monitored 70 ms 70 ms 70 ms 70 ms
reset with falling
edge max.

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Times 750124 750154 751124 751154

Delay-on de-energi-
sation
With E-STOP typ. 10 ms 10 ms 10 ms 10 ms
With E-STOP 20 ms 20 ms 20 ms 20 ms
max.
With power failure 40 ms 40 ms 40 ms 40 ms
typ.
With power failure 80 ms 80 ms 80 ms 80 ms
max.
Recovery time at
max. switching fre-
quency 1/s
After E-STOP 50 ms 50 ms 50 ms 50 ms
After power fail- 100 ms 100 ms 100 ms 100 ms
ure
Waiting period with a
monitored reset
With rising edge 120 ms 120 ms 120 ms 120 ms
With falling edge 250 ms 150 ms 250 ms 150 ms
Min. start pulse du-
ration with a moni-
tored reset
With rising edge 30 ms 30 ms 30 ms 30 ms
With falling edge 100 ms 100 ms 100 ms 100 ms
Supply interruption 20 ms 20 ms 20 ms 20 ms
before de-energisa-
tion
Simultaneity, chan- ∞ ∞ ∞ ∞
nel 1 and 2
Environmental data 750124 750154 751124 751154
Climatic suitability EN 60068-2-78 EN 60068-2-78 EN 60068-2-78 EN 60068-2-78
Ambient temperature
Temperature -10 - 60 °C -10 - 60 °C -10 - 60 °C -10 - 60 °C
range
Storage temperature
Temperature -40 - 85 °C -40 - 85 °C -40 - 85 °C -40 - 85 °C
range
EMC EN 60947-5-1, EN EN 60947-5-1, EN EN 60947-5-1, EN EN 60947-5-1, EN
61000-6-2, EN 61000-6-2, EN 61000-6-2, EN 61000-6-2, EN
61000-6-4 61000-6-4 61000-6-4 61000-6-4
Vibration
In accordance EN 60068-2-6 EN 60068-2-6 EN 60068-2-6 EN 60068-2-6
with the standard
Frequency 10,0 - 150,0 Hz 10,0 - 150,0 Hz 10,0 - 150,0 Hz 10,0 - 150,0 Hz
Max. amplitude 0,35 mm 0,35 mm 0,35 mm 0,35 mm

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Environmental data 750124 750154 751124 751154

Airgap creepage
In accordance EN 60947-1 EN 60947-1 EN 60947-1 EN 60947-1
with the standard
Overvoltage cate- III III III III
gory
Pollution degree 2 2 2 2
Rated insulation volt- 250 V 250 V 250 V 250 V
age
Rated impulse with- 4,00 kV 4,00 kV 4,00 kV 4,00 kV
stand voltage
Protection type
Mounting (e.g. IP54 IP54 IP54 IP54
cabinet)
Housing IP40 IP40 IP40 IP40
Terminals IP20 IP20 IP20 IP20
Mechanical data 750124 750154 751124 751154
Mounting position Any Any Any Any
Mechanical life 10,000,000 cycles 10,000,000 cycles 10,000,000 cycles 10,000,000 cycles
Material
Bottom PC PC PC PC
Front PC PC PC PC
Top PC PC PC PC
Cross section of ex-
ternal conductors
with screw terminals
1 core flexible 0,25 - 2,50 mm², 24 0,25 - 2,50 mm², 24 – –
- 12 AWG - 12 AWG
2 core with the 0,25 - 1,00 mm², 24 0,25 - 1,00 mm², 24 – –
same cross sec- - 16 AWG - 16 AWG
tion, flexible with
crimp connectors,
no plastic sleeve
2 core with the 0,20 - 1,50 mm², 24 0,20 - 1,50 mm², 24 – –
same cross sec- - 16 AWG - 16 AWG
tion, flexible with-
out crimp connec-
tors or with TWIN
crimp connectors
Torque setting with 0,50 Nm 0,50 Nm – –
screw terminals
Connection type Screw terminal Screw terminal Spring-loaded ter- Spring-loaded ter-
minal minal
Mounting type plug in plug in plug in plug in
Cross section of ex- – – 0,20 - 2,50 mm², 24 0,20 - 2,50 mm², 24
ternal conductors - 12 AWG - 12 AWG
with spring-loaded
terminals: flexible
with/without crimp
connector

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Mechanical data 750124 750154 751124 751154

Spring-loaded termi- – – 2 2
nals: Terminal points
per connection
Stripping length – – 9 mm 9 mm
Dimensions
Height 98,0 mm 98,0 mm 100,0 mm 100,0 mm
Width 22,5 mm 22,5 mm 22,5 mm 22,5 mm
Depth 120,0 mm 120,0 mm 120,0 mm 120,0 mm
Weight 190 g 210 g 190 g 210 g

The standards current on 2009-12 apply.

Safety characteristic data

Operating EN ISO EN ISO EN IEC EN IEC IEC 61511 IEC 61511 EN ISO
mode 13849-1: 13849-1: 62061 62061 SIL PFD 13849-1:
2006 2006 SIL CL PFHD [1/h] 2006
PL Category TM [year]
Safety con- PL e Cat. 4 SIL CL 3 2,31E-09 SIL 3 2,03E-06 20
tacts, instan-
taneous

All the units used within a safety function must be considered when calculating the safety
characteristic data.

Information
A safety function's SIL/PL values are not identical to the SIL/PL values of
the units that are used and may be different. We recommend that you use
the PAScal software tool to calculate the safety function's SIL/PL values.

ATTENTION!
It is essential to consider the relay's service life graphs. The relay outputs'
safety-related characteristic data is only valid if the values in the service life
graphs are met.

The PFH value depends on the switching frequency and the load on the relay output. If the
service life graphs are not accessible, the stated PFH value can be used irrespective of the
switching frequency and the load, as the PFH value already considers the relay's B10d val-
ue as well as the failure rates of the other components.

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Order reference
Order reference
         

Order
Product type Features   Terminals no.
PNOZ s4.1 24 VDC Screw terminals 750 124
PNOZ s4.1 C 24 VDC Spring-loaded terminals 751 124
PNOZ s4.1 48 - 240 VAC/DC Screw terminals 750 154
PNOZ s4.1 C 48 - 240 VAC/DC Spring-loaded terminals 751 154

EC declaration of conformity
This product/these products meet the requirements of the directive 2006/42/EC for machin-
ery of the European Parliament and of the Council. The complete EC Declaration of Con-
formity is available on the Internet at www.pilz.com/downloads.
Representative: Norbert Fröhlich, Pilz GmbH & Co. KG, Felix-Wankel-Str. 2, 73760 Ostfil-
dern, Germany

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 Back cover

...

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Internet:
headquarters.
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Pilz GmbH & Co. KG

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In many countries we are

www.pilz.com
73760 Ostfildern, Germany
Telephone: +49 711 3409-0
Please refer to our homepage

pilz.gmbh@pilz.de
+49 711 3409-133
represented by our subsidiaries

for further details or contact our

support@pilz.com
+49 711 3409-444
Technical support
InduraNET p®, Pilz®, PIT®, PMCprotego®, PMI®, PNOZ®, Primo®, PSEN®, PSS®, PVIS®, SafetyBUS p®, SafetyEYE®, SafetyNET p®, the spirit of safety® are registered and protected trademarks 21890-EN-05,
Sachnummer 2013-05 Germany
Printed inPrinted in Germany
of Pilz GmbH & Co. KG in some countries. We would point out that product features may vary from the details stated in this document, depending on the status at the time of publication and the scope © Pilz
© Pilz GmbH & Co. KG,GmbH
2011 & Co. KG, 2011
of the equipment. We accept no responsibility for the validity, accuracy and entirety of the text and graphics presented in this information. Please contact our Technical Support if you have any questions.